ORION AUTOMATION PLATFORM in PROCESS PLANTS ORION APPLICATION NOTE

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1 ORION AUTOMATION PLATFORM in PROCESS PLANTS ORION APPLICATION NOTE

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3 The Orion Automation Platform from NovaTech is being applied in process plants to reduce cost and complexity in the following applications: 1. Protocol conversion and media conversion, primarily conversion from uncommon or proprietary serial protocols to Modbus TCP 2. Integration of large large numbers of IEDs (Intelligent Electronics Devices) from substations and load centers 3. 1ms Sequence of Events (SOE) Recording 4. Lower-cost web-based HMI (Human-Machine Interface) and SCADA systems for portions of the plant This document describes Orion applications in each of these area and summarizes key Orion features and benefits. TABLE OF CONTENTS ORION OVERVIEW... 4 PROTOCOL CONVERSION AND MEDIA CONVERSION... 8 Orion polls real-time data from attached IEDs using the native IED protocol and presents data to the DCS in a different protocol. INTEGRATION OF LARGE NUMBERS OF INTELLIGENT ELECTRONIC DEVICES...10 Orion(s) polls IEDs in substations, motor control centers (MCCs) and other process areas and presents scaled and consolidated data to the DCS. 1ms SEQUENCE OF EVENTS (SOE) RECORDING...14 Orion Distributed I/O modules time-stamp discrete and analog events to 1ms accuracy. Orion consolidates SOE events and presents to user. SMALL WEB-BASED SCADA...17 Orion polls and archives data from a substation and serves out customized webpages. OTHER ORION APPLICATIONS IN PROCESS PLANTS l ORION FOR PROCESS PLANTS

4 ORION OVERVIEW What is the Orion Automation Platform? The Orion Automation Platform is a family of modular hardware platforms and software designed to perform a range or monitoring and control applications. Originally designed for accessing data from IEDs (Intelligent Electronic Devices) in unconditioned and noisy electrical substations, Orion provides a rugged solution for accessing data from nearly any intelligent serial or Ethernet plant device, plus options to present these data where and how the user desires: to plant control systems, to plant databases, to HMIs (Human-Machine- Interfaces), etc. OrionLX Physical Overview MultiMedia Board with Third Ethernet Port and VGA Port High Performance CPU Option Expanded Memory Options 16 Optional Serial Ports Standard IRIG-B Port (for time synch.) Single or Redundant Power Supplies Standard Front RS-232 Port and USB Port Standard RS-232 Port Diagnostic LEDs V.34 Phone Modem Single or Dual Ethernet ORION AUTOMATION APPLICATION NOTE l 4

5 How is Orion Applied in Process Plants? HMIs Plant Databases Process Control System Process Areas Plant Substations Real-Time process data inputs Settings and control outputs Real-Time Amps, Volts, Watts, VARs, etc. inputs Breaker TRIP/CLOSE commands and settings outputs Orion Orion Serially-accessed plant instrumentation using protocols not supported by the Process Control System Sequence of Events (SOE) I/O Modules Panel Meters Protective Relays Specialized Controllers Orion provides real-time data to process control systems and plant databases. These data are accessed from the IEDs in plant process areas and plant substations. Control commands, such as circuit breaker TRIP/ CLOSE, can be sent through Orion either to I/O modules or to the microprocessor protective relay on the breaker. 5 l ORION FOR PROCESS PLANTS

6 How Does Orion Access Data? HMIs Plant Databases Process Control System Plant systems poll data from Orion Orion Orion polls data from IEDs In this diagram, data flow, from IEDs to plant systems, is represented by bricks. Orion polls a subset of the data available from the IEDs. Plant systems poll all or a portion of the data from Orion. Note Orion polls data asynchronously to how it is polled (e.g. Orion could poll IEDs every second, while the DCS could poll Orion every two seconds). ORION AUTOMATION APPLICATION NOTE l 6

7 Summary of Typical Orion Applications Protocol Conversion Modbus TCP to DNP3 (common utility protocol) Modbus TCP to SEL Protocol (for Schweitzer Relays) Modbus TCP to ABB 10-byte (for ABB DPU2000 relays) Modbus TCP to Modbus serial (PLCs, most GE motor relays, many starters and drives) Modbus TCP to proprietary instrumentation protocols (e.g. SCPI) Media Conversion Serial RS-232 to Ethernet Serial RS-485 to Ethernet Serial Fiber Optic to Ethernet Remote Terminal Unit Report real-time data to SCADA or to DCS Accept control commands from SCADA or from DCS Can obtain data from IEDs or from Orion I/O modules Security Gateway Secure connections between DCS and IEDs Strong password and password rules Firewall Encryption Logging Human-Machine-Interface (HMI) Serve out customized webpages to browsing PC locally or remotely Local control and tagging supported Direct Video monitor connections to Orion supported (to eliminate browsing PC) Math and Logic Control IEC available for local control tasks Rugged Orion I/O modules available Alarm Annunciation Serve out webpages with alarms status Acknowledge alarms locally or remotely Tile Annunciator available Sequence of Events (SOE) Recording 1ms accuracy Works with Orion Distributed I/O 7 l ORION FOR PROCESS PLANTS

8 PROTOCOL CONVERSION AND MEDIA CONVERSION Protocol Conversion and Media Conversion at Southeast US Nuclear Fuel Processing Plant In a Southeast US nuclear fuel processing plant, Orion Automation Platforms convert data from specialty instruments in their native protocols to the plant NovaTech DCS in Modbus TCP protocol. Keithly Electrometer Temperature Pressure Humidity ph SCPI Protocol (Orion Protocol #22) NovaTech D3 Console Modbus TCP Protocol Generic ASCII Protocol (Orion Protocol #GASC #33) Digiquartz Protocol (DQI Orion Protocol #29) GE Moisture Monitor Series 3 Panametric Hygrometer Paroscientific k-101 Pressure Transmitter NovaTech PCMs Key Orion Features for Protocol Conversion Large Orion library of communications protocols over 50 total including many for Process applications NovaTech Engineering can add protocols to Orion for a small one-time fee NovaTech Generic ASCII protocol enables users to create interfaces to ASCII devices Serial Protocols for Process Applications Network Protocols for Process Applications DNP3 Level 2 / Slave DNP3 TCP/UDP / Slave Modbus RTU / Slave Modbus TCP RTU / Slave SEL ASCII Protocols NTP Client / Server SEL2030 Protocol SNMP Client TransData DTO FTP / sftp Server Alstom KITZ (Courier) HTTP / HTTPS Server GE DLP telnet / SSH Server ABB DPU and 10-byte PassThru Server DF1 (Allen Bradley) SCPI (Std. Commands for Programmable Inst.) Generic ASCII IEC DQI (Digiquartz) ORION AUTOMATION APPLICATION NOTE l 8

9 INTEGRATION OF LARGE NUMBERS OF INTELLIGENT ELECTRONIC DEVICES Integration of Intelligent Electronic Devices at a Northeast US Cocoa Processing Plant In a US cocoa processing plant, multiple Orion platforms integrate over 600 motor overload relays, drives and softstarts. Real time data values, including operation status, fault status and measured values, are presented to the plant NovaTech D/3 DCS. To D/3 PCM using Modbus TCP/IP Via Ethernet Switch Orion RS-485 Modbus 144 Square D overload relays per Orion (528 devices total attached to multiple Orions) Summary of Cocoa Plant Application Data Provided: MLP II FAULT STATUS BITS MLP II OPERATIONAL STATUS BITS MLP II Raw Average Current MLP II Thermal Capacity Rating Information to Orion database, then to D/3 database, and to TotalVision display screens 528 Square D MotorLogic Plus II (MLP II) Overload Relays in Square D Motor Control Centers Orion also accesses data from these IEDs: Altivar Drives 64 Devices 4 read registers, 1 analog write register for speed 4 registers to be remapped to contiguous Modbus registers to simplify reading by DCS TCP/IP connection to PCM ports via Modbus TCP/IP Square D SoftStarts 13 Devices 4 registers read 1 write for settings connections TCP/IP connection to PCM ports via Modbus TCP/IP 9 l ORION FOR PROCESS PLANTS

10 Integration of Intelligent Electronic Devices at Midwest US Agricultural Product Processing Plant Eleven Orion Automation Platforms are installed in two substations and nine motor control centers to access real-time data from trip units and protective relays: (2) New Substation at Dry Grind Facility (1) Dry Grind Medium Voltage (1) Mill Motor Control Center (1) Feedhouse Motor Control Center (1) D/D Motor Control Center (1) Utility Motor Control Center (1) Elevator Motor Control Center (1) DDGS Loadout Motor Control Center (1) Alcohol Loadout Motor Control Center (1) Waste Treatment Motor Control Center These data are made available to the plant NovaTech D/3 DCS. Interface to Eaton MCCs To PCM Modbus TCP Orion5r Modbus Serial RS-485 Proprietary Incon Network Modbus MINT (mmint) Modbus-to-INCOM converter Eaton Digitrip Trip Units on MCCs ORION AUTOMATION APPLICATION NOTE l 10

11 Performance Guidelines: RS-485 Multidrop Updates from each of the points from each IED can be obtained every 1 to 2 seconds Four IEDs on each RS-485 Modbus network 100 data values from each 11 l ORION FOR PROCESS PLANTS

12 Key Orion Features for IED Integration Up to 16 RS-485 serial ports per Orion; each port able to accommodate up to 31 IEDs Large point processing capabilities; up to 20,000 points able to be accessed and presented to DCS IED Point Pick Lists Simple mapping of points from the ports where data is polled by Orion to ports where the DCS will poll data from Orion (no typing) RS-485 with IRIG-B Bit-to-Byte Converter RS-232 Port with IRIG-B Fiber Optic ST Connector RS-485/RS-422 Two-Wire or Four-Wire Fiber Optic with IRIG-B V-pin Connector Fiber Optic RS-232 RS-485 Serial communication cards are modular and field-upgradable ORION AUTOMATION APPLICATION NOTE l 12

13 Orion Point Pick Lists Orion is supplied with over 300 point pick lists. These point pick lists contains the names and addresses of all of the points that can be read, or controlled, by Orion. These preformatted lists make configuration possible with minimal typing and scripting Point pick lists for many process plant IEDs are provided including: Bitronics Meters and Recording IEDs; all models GE Protective Relays; UR Series, DLP Series, 7xx Series, 469 Series, 269 Series GE Meters; PQM Series Schweitzer Protective Relays; all models Basler and Beckwith Protective Relays; most models Square D MLPII Motor Relays Eaton DigiTrip IEDs Satec, Power Measurement, and Electro- Industries Meters Ametek GenStar Meters The pick list in the left column contains all of the 1486 point available in this GE 469 Motor Relay. The middle column show the 22 points that are selected to be read by Orion. The column at the right displays parameters of selected points. The Outputs tab lists all of the points that can be turned ON or OFF by Orion. 13 l ORION FOR PROCESS PLANTS

14 1ms SEQUENCE OF EVENTS (SOE) RECORDING 1ms Sequence of Events (SOE) Recording at Midwest Cogeneration Plant Orions and Distributed SER I/O Modules are applied to place 1ms time stamps on power system events. A redundant architecture, including dual D/3 PCMs and dual RS-485 and Ethernet connections to the I/O modules, assures higher availability. D/3 PCM 1A MPC II D/3 PCM 1B MPC II D/3 PCM 2A MPC II D/3 PCM 2B MPC II Computer Room Orion Cabinet 1 Orion Cabinet 2 Orion5r Orion5r Ethernet Orion5r Orion Distributed SER Modules Orion Distributed SER Modules RS-485 Equipment Layout - Cogeneration Plant ORION AUTOMATION APPLICATION NOTE l 14

15 Typical D/3 TotalVision screen depicting integration of Orion Sequence of Events system with D/3 PCMs. Also shown: web-based HTML table of 1mS time-stamped SOE data from substation IEDs and Orion I/O modules. Sequence of Events Recording with Orion and Distributed I/O The connections and data flow between Orion and I/O modules in this SOE system are summarized below: 3) Orion reads all change events using DNP3 protocol. Time stamps are included with all change events. 2) Orion I/O places a time stamp on each switch change. Orion I/O internal clock is synchronized to external source (IRIG-B or NTP). 4) PC running browser reads web pages served out from Orion containing time-stamped event data or event data sent out as.csv file from Orion or event data accessible via SQL queries sent to Orion. 1) Orion I/O monitors field contact state changes. 15 l ORION FOR PROCESS PLANTS

16 Sequence of Events Recording with Orion and Distributed I/O Physical Features Operates with 48V dc or 125V dc battery-powered systems No converters or interposing relays required All input circuits independent and isolated Simplifies retrofits Both Ethernet and serial options supported Rugged design to survive in harsh environments -25 C to 70 C (156 F) Meets stringent IEEE C37.90 standards for Fast Transients, Electrostatic Discharge and RFI Software Features Internal clock can be synchronized to a precise IRIG-B time signal Facilitates time stamping to an accuracy of one millisecond Network Time Protocol (NTP) also supported when access to NTP server is available Individual filters on all discrete input channels to reduce nuisance data ON-state filter De-bounce filter Chattering contact filter DNP3 Protocol Supports transfer of timed events in the protocol When combined with Orion, presents SOE data in multiple forms to meet specific user requirements Table of SOE events presented on a web page Exported.csv file SQL queries from other databases DDIO 19 rack-mount model, front and rear view. Panel mount and DIN-rail mount models also available. ORION AUTOMATION APPLICATION NOTE l 16

17 SMALL WEB-BASED SCADA OrionLX-Based WEBserver SCADA at Midwest US Agricultural Product Processing Plant Plant Need: A monitoring system to identify root causes for power system interruptions. Solution: Install Orions and Orion Distributed I/O modules in the substation to access data from IEDs and to capture high-speed (1ms) SOE data Provide simple web-based local visualization of power system operation and power system data Provide SOE data to utility operators via preconfigured web pages in Orion Automation Equipment Interconnections - WEBserver SCADA Application Orion #1 In control House outside fence Webpages served from Orion #1 Fiber Ethernet Slave Orion #3 Protective Relays in Switchgear Line-up #1 Protective Relays in Switchgear Line-up #2 Protective Relays in Switchgear Line-up #3 Slave Orion #2 To serially-connected meters and Protective Relays 17 l ORION FOR PROCESS PLANTS

18 Slave OrionLX #2 IED Connections Electro Industries CPU 1000 Futura Meter RS-485 DNP3 RS-232 DNP3 RS-232 DNP3 RS-232 DNP3 RS-232 DNP3 Beckwith M-2001C Regulator SEL-321 Protective relay SEL-501 Protective relay SEL-387 Protective relay Slave OrionLX #3 IED Connections BUS 3 BUS 2 BUS 1 BUS 3 BUS 2 BUS 1 (6) ABB DPU2000 Protective Relays (30) GE Multilin 750 Protective Relays ABB 10-byte Protocol RS-485 DNP3 Protocol RS-485 ORION AUTOMATION APPLICATION NOTE l 18

19 Webpages (Screens) Provided in System OrionLX #1 serves out standard and customized webpages providing specific power system data. These data are used by engineers and operators to identify root causes of power interruptions. Sequence of Events Screen Sequence of Events Screen summarizes all logged 1mS time-stamped events in a pre-formatted tabular text. Alarm Screen displays power system alarms (in alarm, not acknowledged, in alarm acknowledged, went out of alarm but not acknowledged) in a a pre-formatted color-coded tabular text summary. Communications Screen depicts communication status to and from all power system IEDs connected to Orion. 19 l ORION FOR PROCESS PLANTS

20 One-line Overview Screen Substation One-line Screen depicts the three phase electrical system showing conductors, breakers, transformers and other power system components with real-time data superimposed. IED Zoom Screen IED Zoom Screen provides a detail screen of IED data and power system from specific circuits. Also presents breaker control options to the user. ORION AUTOMATION APPLICATION NOTE l 20

21 OTHER ORION APPLICATIONS IN PROCESS PLANTS In the electric utility industry, Orion also performs a role in critical cyber security, energy management and fast automatic restoration applications. Process plants with challenges in these areas may benefit from the application of Orion. Security Where very high communication security is required, the connection between an OrionLX and a remote server, or between a local OrionLX and a remote OrionLX, can be locked down with a VPN (e.g. OpenVPN). Strong passwords in Orion, and the Orion firewall, provide additional levels of security. An unalterable syslog records all user access attempts and processes accessed on Orion. Automatic Restoration The combination of high-speed math and logic, substation-grade I/O and access to protective relay data make Orion ideal for tie-breaker control in substations. Energy Management Orion can provide the real-time energy data from substation IEDs and load center IEDs required for energy management systems, such as the NovaTech Energy and Asset Management System (EAMS). Copyright 2012 NovaTech, LLC. All rights reserved. NovaTech and Bitronics are registered trademarks of NovaTech, LLC. SEL is a registered trademark of Schweitzer Engineering Laboratories, Inc. The information in this literature is subject to change without notice and is not to be construed as a warranty. AN_OrionProcessPlants_ Contact: NovaTech, LLC Orion Utility Automation West 107th Street Lenexa, KS T: F: E: orion@novatechweb.com ORION AUTOMATION APPLICATION NOTE l 21